B7 Stud Failure

PTFE-coated stud failure

 Pipefitters broke three studs while making
up flanges.
 Two studs broke while tightening with
hand wrenches, a third broke while
tightening with a torque wrench.
 Pipefitters reported the incident to the
plant maintenance engineer.
 PTFE-coated stud failure
 One of the failed studs was tested and broke
at ~40 ft-lbs (54 N-m).
 PTFE-coated stud failure
 Cross-Section of failed stud

Void space in metal (~1/16” wide)

 PTFE-coated stud failure
 All of the bad studs
were ¾”-10 x 4.75”
long.
 Manufactured by “SUN”
as stamped on the stud.
 PTFE-coated stud failure
 Metallurgical testing has found that it is possible
for these defective studs to be torqued to 150 ft-
lbs without breaking. Thus, there could be some
of these studs installed on piping in our facilities.
 The inspection and metallurgy group have
devised a method to use an ultrasonic probe to
test the integrity of the studs in place.
 PTFE-coated stud failure
 The defect appears to be only in the ¾”-
10 x 4.75” long studs. Other sizes from
“SUN” tested fine.
 Project and maintenance groups have
been advised to quarantine any “SUN”
studs they find and not to use them.
 PTFE-coated stud failure
 Supplier is replacing all “SUN” studs with
new studs from an alternative
manufacturer.
 Supplier has assured us that “SUN” studs
will no longer be purchased.